00 Course Introduction NEW Downloads... · PDR - Product Design Review CDR - Critical Design Review PRR- Production Readiness Review TRR- Test Readiness Review SAR - System Acceptance

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thebenshimagroup © 2008 00. Course Introduction

  Purpose –  Learning objectives –  “Design” –  Audience

  Projects –  Types –  Students –  Advisors –  Sponsors

  Design process –  Capstone vs. NASA vs.

the book –  Project milestones

  Class –  Integration with projects –  Assignments –  Notes

  Texts and resources   Syllabus   Facilities and resources

–  Meeting –  Building

  Grading –  Elements

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 How to develop products to exceed customer requirements and expectations

 This is the real thing  We’re betting on you with our resources

and reputation


  The Capstone Design course requires that students work in teams on “open-ended” engineering design projects. Students are given the opportunity to realize original and creative solutions to real engineering problems, not merely design changes of scale or duplication of existing systems. Important topics are presented in the lectures including the design process, design tools, project management, engineering communication, engineering ethics, and intellectual property. Students are encouraged to take on new team roles and to test the limits of their capabilities.

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  Students will understand the importance of a structured design process

  Students will understand and be able to implement the five phases of a structured design process

  Students will be able to implement the key tools of a structured design process

  Students will gain practice in working on self-managed teams

  Students will gain confidence in their abilities to deliver an engineering solution from need to parts


  Development of student creativity   Use of open-ended problems   Alternate design solutions and decision rationale   Use of modern design theory and methodologies   Formulation of design statements and specifications   Feasibility consideration   Consideration of production processes   Concurrent engineering design   Detailed system description   Use of teams in problem solving and design   Realistic constraints (DFX, economics, etc.)   Development of related communication skills   Success in a globally competitive world

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  … the systematic and creative application of scientific and mathematical principles to practical ends such as the design, manufacture, and operation of efficient and economical structures, machines, processes, and systems. www.iteawww.org/TAA/Glossary.htm

  … a function in the product creation process where a good is configured and specific form is decided. www.shapetomorrow.com/resources/e.html

  … the process of devising a system, component, or process to meet desired needs. The primary way that engineers utilize the forces and materials of nature for the benefit of mankind is through new and innovative designs (from ABET). http://civil.engr.siu.edu/intro/design.htm


  … the creative, iterative and often open-ended process of conceiving and developing components, systems and processes. Design requires the integration of engineering, basic sciences and mathematics. A designer works under constraints, taking into account economic, health and safety, social and environmental factors, codes of practice and applicable laws. www.ee.wits.ac.za/~ecsa/gen/g-04.html

  … an activity in the product creation process where a good is configured. Specific form is decided. The activity is sometimes seen as a late step in the R&D process and sometimes as an early step in the manufacturing process. www.faculty.catawba.edu/jbgreen/Dr.Green/glossary.htm

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  Engineering design is the communication of a set of rational decisions obtained with creative problem solving for accomplishing certain stated objectives within prescribed constraints. Lumsdaine et al., p. 316

  Design establishes and defines solutions and pertinent structures for problems not solved before, or new solutions to problems which have previously been solved in a different way. … The ability to design is both a science and an art. … Good design requires both analysis and synthesis. Dieter, pp.1-3

  Design incorporates creativity, complexity, making choices between many possible solutions, and compromise in balancing many (sometimes conflicting) requirements. Dieter, pp.1-3


  Capstone Design is intended for engineering students that have completed all of the core requirements of their education

  The purpose of the course is to teach students how to implement a structured design process on a real project in a team (perhaps multi-functional) environment

  Teams can contain a mix of students in various years as long as they are all exposed to the design process material

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  Teams of 4 or more students work on one sponsored project lasting two semesters

  Projects encompass the entire design process — ideation through functional prototype build and evaluation

  The first semester ends with a formal project review, reflective of a typical stage-gate process, in which each team demonstrates their design progress to date and gain approval for their plan to complete the project during the second semester

  The second semester concludes with a project-ending full presentation before industry representatives, faculty members, and their peers

  Typical projects are design-intensive, where the team may be asked to develop a new product, design and build a portion of a new manufacturing process cell, or fabricate a special machine designed for a specific task


Project # 14: Advanced Filtration System Sealing

PURPOSE: The purpose of this project is to design an advanced sealing mechanism for an Advanced Filtration System. This system will be utilized on engine applications.

TIMEFRAME: This is a project that will be worked on in Senior Design starting XXXX and XXXX.

PROJECT SCOPE: This team will be comprised of five senior Mechanical Engineering students. The project we have selected focuses on designing an advanced sealing mechanism for our Advanced Filtration System. The system is to be utilized on engine applications. We are still in the development stage on this program. There are development prototypes built and installed on test vehicles now. One of the components of the filter is currently a rubber inflatable seal. The seal's function is to provide a positive seal between the inlet and exit cavities of the filter unit during filtration. When the filter media is plugged, there is a mechanism on board that allows for new media to be advanced into the filtering window. In order to do this, the seal must disengage/retract. In its current state the seal is deflated. Once the seal retracts the filtering media can be advanced. These inflatable seals have been a reliability issue for us. As you can probably guess, it has been a fatigue issue related to the inflating and deflating of the seal. We have solved the fatiguing problem. However, the solution is a more expensive inflatable seal that is fabric reinforced. This solution has allowed us to continue our field testing. It is now time to look at a less expensive solution for a production design.

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  This course is developed around having sponsored projects

  Ideally the projects are paid for by an outside group that is truly committed to the project

  This commitment gives the project financial resources as well as a “customer”

  Even if there is no financial commitment, each project should have a customer that is external to the class that “needs” the final product

  It is important to remind sponsors that not all student projects are successful


  Each student will participate in a team project   This is the most important element of the class   The project is designed to be their first project outside

of school and should be treated as a job   The goal is to give them that experience with fewer

ramifications for project failure   Each person will be expected to participate in the

team and work on the project professionally   Each sponsor and advisor will expect a finished,

documented project completed to their expectations

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  The advisor and sponsor are also responsible for project success

  The role of the advisor is to help guide the team through the design process, offer advice when appropriate, steer when necessary, and help find information when necessary

  This is accomplished through at least one weekly, hour-long meeting

  The advisors should not be expected to be the sole source for technical information nor necessarily the primary source


  The advisor and sponsor are also responsible for project success

  The sponsors represent their own interests   The team is expected to serve those interests

within the guidelines set by the advisor   Groups should meet frequently with their

sponsors – in person and by teleconferencing or videoconferencing

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Weighted User Requirements

Project Analysis Statement

Design Project Proposal

Project Plan

Quantitative Design

Constraints Project Description Design

Evaluation Plan

Project Approval Document

PCR

Team Organization Design

Concept Keys

Pugh Evaluation Technology

Readiness Assessment QFD

Concept Sketches

Concept Benchmarks Functional

Description

SRR

SDR

Detailed Design Concept Drawings Bill of

Materials Construction/

Assembly Drawings

Parameter Analysis FMEA Simulation Functional

Testing DfX

Refined System Concept

DOR

PDR

Detailed Design

Drawings Production

Specifications Production Plan

Detailed Design Drawings and Specifications

System Optimization

Prototype Testing

Refined Parameter

Design

DOR

CDR PRR

Fabrication

TRR

SAR

Final Design

ORR

Pre-Phase A Design Problem

Analysis

Phase A System Level

Conceptual Design

Phase B Parameter Level

Design

Phase C Optimized

Parameter Design

Phase D Fabrication, Assembly,

and Testing

Review Points PCR - Project Concept Review SRR - System Requirements Review SDR - System Design Review DOR - Design Objectives Review PDR - Product Design Review CDR - Critical Design Review PRR - Production Readiness Review TRR - Test Readiness Review SAR - System Acceptance Review ORR - Operational Readiness Review

Assembly

Testing

Design Objectives w/

Targets

Final System Delivered Parameter Level

Design Proposal Best System Concept Proposal

REVIEW


CDR Critical Design Review DfX Design-for-X DOR Design Objectives Review

FMEA Failure Modes and Effects Analysis ORR Operational Readiness Review PCR Project Concept Review PDR Product Design Review PRR Production Readiness Review QFD Quality Function Deployment SAR System Acceptance Review SDR System Design Review SRR System Requirements Review TRR Test Readiness Review

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NASA Capstone Design Lumsdaine Pre-Phase A

Concept Studies Design Problem Analysis Design Problem Analysis

Phase A

Concept and Technology Development System Level Conceptual Design Conceptual(System) Level Design

Phase B

Preliminary Design and Technology Completion Parameter Level Design Parameter Level Design

Phase C

Final Design and Fabrication Optimized Parameter Design Optimized Parameter Design

Phase D

Assembly, Integration, and Test Launch Fabrication, Assembly, and Testing -


NASA Capstone Design Lumsdaine

Pre-Phase A

MCR- Mission Concept Review IPR- Informal Proposal Review

Program/Project Proposals Preliminary Mission Concept Report

PCR- Project Concept Review Project Approval Document

Review by Instructor, Advisor, and Sponsor Design Project Proposal

Phase A

SRR- System Requirement Review SDR- System Definition Review

SRR- System Requirement Review SDR- System Design Review Design Concept Keys

Design Decisions

Phase B

PDR- Program Definition Review Preliminary Design Report

Interface Control Documents

DOR- Design Objectives Review PDR- Product Design Review

Refined System Concept

Review by Instructor, Advisor, Team, and Sponsor

Design Project progress Report

Phase C

CDR- Critical Design Review PRR- Production Readiness Review Preliminary Operations Handbook

DOR- Design Objectives Review CDR- Critical Design Review

PRR- Production Readiness Review Refined Parameter Design

Design review panel and Instructor – Oral Presentation Review Final progress Report

Phase D

TRR- Test Readiness Review SAR- System Acceptance Review

ORR- Operational Readiness Review Verification and Validation Report

Operator and Maintenance Manuals

TRR- Test Readiness Review SAR- System Acceptance Review

ORR- Operational Readiness Review Final Design

-

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REVIEW CONTENT TIMING AUDIENCE

PCR Design Project Proposal Pre-Phase A Sponsor, Advisor

SRR Pugh Evaluation Phase A - Mid Sponsor, Advisor

SDR Best System Concept Proposal Phase A - End Sponsor, Advisor, Faculty, Peers

DOR (Phase B) Results from Parameter Analysis, FMEA, Simulation, Functional Testing, DfX Phase B - Mid Sponsor, Advisor, External

technical advisors

PDR Parameter Level Design Proposal Phase B - End Sponsor, Advisor, Faculty, Peers

CDR Detailed Design Drawings and Specifications Phase C - Mid Sponsor, Advisor

DOR (Phase C) Results from System Optimization and Prototype Testing Phase C - End Sponsor, Advisor, External technical advisors

PRR Detailed Design Drawings and Specifications Phase C - End Sponsor, Advisor, Fabrication resource

TRR Results after Assembly Phase D - Begin Sponsor, Advisor

SAR Testing Results Phase D - Mid Sponsor, Advisor, External technical advisors

ORR Testing results after passing SAR Phase D - End Sponsor, Advisor, Faculty, Peers



MCR Mission goals and objectives Preliminary risk assessment Pre-Phase A Internal

SRR System architecture System requirements document Phase A - Mid Technical team, Project

Manager & Review Chair

SDR System architecture Preliminary functional baseline Phase A - End Technical team, Project


PDR Preliminary subsystem design specifications Applicable technical plans Phase B - End Technical team, Project


CDR

Product build-to specifications Operational limits and constraint

Fabrication, assembly, integration, and test plans and procedures

Phase C - Mid Technical team, Project Manager & Review Chair

PRR Design documentation for production Phase C - Mid Technical team, Project Manager & Review Chair

TRR System and subsystem qualification testing results Document with objectives for testing Phase D - Begin Technical team, Project


SAR Results of SAR at all suppliers Manufacturing plans Phase D - Mid Technical team, Project


ORR Operational supporting and enabling products Results of all completed validation tests Phase D - End Technical team, Project


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Review by Instructor, Advisor,

and Sponsor Design Project Proposal Oral Team Presentation

Pre-Phase A Instructor, Advisor and Sponsor

Review by Instructor, Advisor, Team, and Sponsor

Design Project Progress Report Phase B Instructor, Advisor, Team, and Sponsor

Design review panel and Instructor – Oral Presentation

Review

Final Progress Report Oral Presentation Phase C

Design Review Panel, Instructor


REPORT CONTENT TIMING AUDIENCE Project Approval

Document Reviewed Design Project Proposal Pre-Phase A Sponsor, Advisor

Refined System Concept Reviewed results from DOR in Phase B Phase B Sponsor, Advisor,

Technical writer

Refined Parameter

Design Reviewed results from DOR in Phase C Phase C Sponsor, Advisor

Final Design Reviewed results from SAR and ORR Phase D Sponsor, Advisor, Technical writer

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REPORT CONTENT TIMING AUDIENCE Design Project

Proposal Project Concept Statement, Design Constraints, Project Analysis Statement Pre- Phase A

Design Decisions Pugh Evaluation Results Phase A

Design Project progress Report Construction/Assembly Drawings and Bill of Materials Phase B

Final progress Report Design Drawings and Specifications, Optimized

Designs Phase C


Module Description

00 Course Introduction

01 The Design Process

02 Team Organization

03 Project Description

04 Project Requirements

05 Project Planning

06 Conceptual Design

07 Pugh Evaluation

08 Quality Function Deployment

09 System Design Review

10 Failure Modes and Effects Analysis

11 Design-for-X

12 Parameter Analysis

13 Parameter Level Design Proposal

14 System Optimization

15 Prototyping and Testing

16 Detailed Design Drawings

17 Fabrication, Assembly, and Testing

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  It is important to keep the project as the topic of the lecture

  All lecture topics should be framed in terms of what students need to do on their projects

  Students MUST use a structured design process, even when less formal procedures would suffice

  It is my feeling that additional, non-project assignments and exams do not add to the quality of the learning but can cause “mutinies”


  If it is necessary for the course (as opposed to the advisor and the project) to dictate assignments, make sure that the assignments are part of the critical path of ALL projects

  One significant issue with sponsored projects (or even different projects) is that they will have differing milestone timelines and make blanket due dates impractical

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 The notes in this course are designed for you to give to your students BEFORE the lecture

 You can then use your knowledge of the design process and your design experiences to help them “fill in the gaps”


  Main text –  Creative Problem Solving and Engineering Design, Edward

Lumsdaine, Monika Lumsdaine, and J. William, Shelnutt, McGraw-Hill College Custom Series, New York, 1999

  Additional suggested texts –  Engineering Design, 3rd Edition, George E. Dieter, McGraw

-Hill, Boston, 2000 –  A Guide to Writing as an Engineer, David Beer and David

McMurrey, John Wiley & Sons Inc., New York, 1997 –  Patent Fundamentals for Scientists and Engineers, 2nd

Edition, Thomas T. Gordon and Arthur S. Cookfair, Lewis Publishers, CRC Press LLC, Boca Raton, 2000

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  Bahill,T.A., Gissing,B.,Re-evaluating System Engineering Concepts Using Systems Thinking, IEEE Trans. on Systems,Man and Cybernetics, v.28(4),p.516-527, 1998.

  Ullman,D.G., The Mechanical Design Process,3rd edition, McGraw-Hill, 2003.   System Engineering Paper Submission Template, http://education.ksc.nasa.gov/ESMDspacegrant

/SE_Paper_Submission_Template.doc   Blanchard,B.S., Fabrycky,W.J., System Engineering and Analysis, 2nd edition, Prentice Hall, 1990.   ANSI/EIA 632-1998, Processes for Engineering a System, Electronic Industries Alliance, 1999.   Introduction to Engineering with the Use of Case Studies, Raju,P.K., Sankar,C.S.,Institute for STEM Education and Research,

2007   Space Mission Analysis and Design, 3rd edition (Space Technology Library) (Space Technology Library) (Paperback) by Wiley J.

Larson (Editor), James R. Wertz (Editor)   Spacecraft Systems Engineering 3rd Edition (Paperback) by Peter Fortescue (Editor), John Stark (Editor), Graham Swinerd

(Editor)   Spacecraft Structures and Mechanisms from Concept to Launch (The Space Technology Library) (Paperback) by Thomas

PSarafin and Wiley J. Larson(Editor)   Space Vehicle Mechanisms: Elements of Successful Design (Hardcover) by Peter L. Conley   The Space Environment: Implications for Spacecraft Design (Paperback) by Alan C. Tribble (Author)   Space Vehicle Design (Aiaa Education Series) (Hardcover) by Michael D. Griffin (Author), James R. French   Fundamentals of Space Systems (The Johns Hopkins University/Applied Physics Laboratory Series in Science and Engineering)

(Hardcover) by Vincent L. Pisacane   Principles of Space Instrument Design (Cambridge Aerospace Series) (Paperback) by A. M. Cruise (Author), J. A. Bowles

(Author), T. J. Patrick (Author)   Elements of Spacecraft Design (Aiaa Education Series) (Hardcover) by Charles D. Brown   Spacecraft Power Systems (Hardcover) by MukundR. Patel (Author)   Spacecraft Thermal Control Handbook: Fundamental Technologies (Hardcover) by David G. Gilmore   Spacecraft Power Technologies (Space Technology) (Hardcover) by Anthony K. Hyder (Author), Ronald L. Wiley (Author), G.

Halpert (Author), Donna Jones Flood (Author), S. Sabripour


  Aircraft Structures for Engineering Students, Fourth Edition (Elsevier Aerospace Engineering) (Paperback) by T. H. G. Megson (Author)

  Printed circuits in space technology: Design and application (Prentice-Hall space technology series) by Albert E Linden   Human Spaceflight: Mission Analysis and Design (Space Technology Series) (Space Technology Series) by Wiley J. Larson and

Linda K. Pranke   Solar Power Satellites: The Emerging Energy Option (Ellis Horwood Library of Space Science and Space Technology. Series in

Space Technology) by Peter E. Glaser, Frank Paul Davidson, and Katlinka I. Csigi   Spacecraft structures (Prentice-Hall international series in space technology) by Carl C Osgood (Unknown Binding - 1966)   Cryogenic engineering (Prentice-Hall international series in space technology) by Joseph H Bell (Unknown Binding - 1963)   Space mechanics (Prentice-Hall international series in space technology) by Walter C Nelson (Unknown Binding - 1962)   Navigation and guidance in space (Prentice-Hall international series in space technology) by Edward V. B Stearns   THE SECOND FIFTEEN YEARS IN SPACE: SCIENCE AND TECHNOLOGY SERIES: VOLUME 31: by Saul (Editor) Ferdman   The Lunar Base Handbook (Space Technology Series) by Peter Eckart (Paperback - Dec 1, 1999)   Technologies of manned space systems (Space flight technology series) by Aleck C Bond (Unknown Binding - 1966)   Metallurgical Assessment of Spacecraft Parts, Materials and Processes (Wiley-Praxis Series in Space Science and Technology)

by Barrie D. Dunn and M. Phil (Paperback - Jun 1997)   Satellite Control: A Comprehensive Approach (Wiley-Praxis Series in Space Science and Technology) by John T.

GarnerIntroduction to space communication systems (McGraw-Hill series in missile and space technology) by George NKrassner

  Robots in Space: Technology, Evolution, and Interplanetary Travel (New Series in NASA History) by Roger D. Launius and Howard E. McCurdy (Hardcover - Jan 7, 2008)

  Recent Developments in Space Flight Mechanics (Science and Technology Series Volume 9) by Paul B. (editor) Richards (Hardcover - 1966)

  The Lunar Sourcebook (Heiken et al) is a good reference. Chapter 3 covers lunar environment.   http://insa.netquire.com/docs/Lessons_Learned_Fina.pdf

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  Students need facilities to conduct team meetings without being interrupted, to conduct phone/video conferences with sponsors, to fabricate their prototypes/deliverables, and to do assembly and testing

  Do not underestimate the resources for this –  Space for projects –  Personnel for a safe fabrication shop


  This course is not a course in how to use a fabrication shop   That is an important class for engineers, but it is expected that

students have completed such a course beforehand   It should be possible for them to complete their project (and

product) within the university, but it is not required   Depending upon the project’s budget, work can be done “out of

house”   Working with contract fabrication allows students to learn much

more about engineering communication

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 A sample syllabus will be included here based upon the test implementation this fall


 Each sponsor and advisor will expect a finished, documented project completed to his or her expectations

  It is important to grade against those expectations as well as the students’ use of a structured design process and the tools therein